JP2021020458A - System and method for laying up composite laminate having integrally laminated filler elements - Google Patents

Abstract

To provide a manufacturing system and method for laying up a stringer laminate.SOLUTION: The manufacturing system includes a plurality of lamination heads such as an outer ply for laying up a frame filler bottom ply at each frame filler location. Also included is at least one frame filler inner ply lamination head for laying up one or more frame filler inner plies over a protruding portion of the frame filler bottom ply at each frame filler location. Further included is at least one stringer body lamination head laying up one or more stringer body plies defining a stringer body portion extending along the lamination surface. A frame filler outer ply lamination head is configured to lay up a frame filler top ply at each frame filler location such that the frame filler inner plies are captured between the frame filler bottom ply and the frame filler top ply.SELECTED DRAWING: None

Description

The present disclosure relates generally to the production of composites, and more specifically to systems and methods for producing composite laminates with integrally laminated filler elements.

Composite structures are used in a wide range of applications due to their high strength-to-weight ratio, good corrosion resistance, and other suitable properties. Increasing amounts of composites are used to manufacture wings, horizontal stabilizers and vertical stabilizers, fuselage, and other components in building aircraft. For example, an aircraft fuselage can be manufactured by assembling multiple composite barrels end-to-end.

The fuselage barrel portion can be made by producing a plurality of molded stringers. Each preformed stringer can be manufactured by laying up and molding a composite laminate (eg, a stringer laminate). Multiple preformed stringers can be attached to a rotatable layup mandrel. A composite material is superposed on this to form an outer panel. The outer panel and the molded stringer are co-cured or co-joined, and the joining structure such as the outer frame is mechanically fixed to the outer panel in the barrel portion. Before installing the mechanical fasteners, the gap between the outer frame and the inner surface of the outer panel must be filled. The conventional method of filling the gap involves producing a composite frame filler, but installing each frame filler is a laborious and time-consuming process, which has a significant effect on the production rate. give.

As is clear from the above, there is a need for systems and methods in the art to avoid increased time and cost associated with the manual fabrication and installation of individual frame fillers.

The above-mentioned needs relating to the manufacture of frame fillers are addressed and mitigated in particular by the present disclosure providing a manufacturing system for laying up stringer laminates. The manufacturing system includes a laminated surface. In addition, the manufacturing system distributes the composite along the distribution direction and is formed on the laminate surface and earlier during the relative motion between the laminate surface and the laminate head along the direction generally aligned with the distribution direction. Includes a plurality of stacking heads configured to stack plies on plies. The plurality of laminated heads include at least one frame filler outer ply laminated head configured to laminate the plurality of frame filler bottom plies at intervals along the laminated surface and define the plurality of frame filler positions. Further, the laminated head is one or more on the protrusion of the frame filler bottom ply at each frame filler position so that the overlapping portion of each frame filler bottom ply is not covered by the frame filler inner ply at each frame filler position. Includes at least one frame filler inner ply stacking head configured to stack a plurality of frame filler inner plies. Further, the laminated head is laminated with one or a plurality of stringer main body plies extending along the laminated surface and defining a stringer main body portion that extends along the laminated surface and overlaps with the overlapping portion at each frame filler position, and each stringer main body ply is placed inside the frame filler. Includes at least one stringer body laminated head configured to be side-by-side with the ply. Further, in the laminated head, one or more frame filler inner plies at each frame filler position are trapped between the frame filler bottom ply and the frame filler top ply, so that the uncured stringer laminate is a stringer. Outside the frame filler configured to stack the top ply of the frame filler on top of one or more inner plies of the frame filler at each frame filler position so as to have multiple frame filler portions protruding laterally from the body portion. Includes ply laminated head.

Further disclosed are methods of laying up stringer laminates. The method comprises using at least one frame filler outer ply lamination head to laminate a plurality of frame filler bottom plies at intervals along the lamination surface to define a plurality of frame filler positions. Further, the method uses at least one frame filler inner ply laminate head to prevent the overlapping portion of each frame filler bottom ply from being covered by the frame filler inner ply at each frame filler position. Includes laminating one or more frame filler inner plies over the overhangs of the plies. In addition, the method uses at least one stringer body stacking head to define one or more stringer body portions that extend along the stacking surface and overlap with the overlap at each frame filler position. This includes stacking one or more stringer body plies and arranging each stringer body ply side by side with the frame filler inner ply. The method uses a frame filler outer ply laminate head to capture one or more frame filler inner plies at each frame filler position between the frame filler bottom ply and the frame filler top ply, resulting in Laminate the frame filler top ply on one or more frame filler inner plies at each frame filler position so that the uncured stringer laminate has multiple frame filler portions that project laterally from the stringer body portion. Including further to do. In some embodiments, the method described above uses a frame filler outer ply stacking head to place at least one frame filler outer ply on a laminated surface at one or more of a plurality of spaced frame filler positions. May include stacking.

Further disclosed are methods of laying up stringer laminates, including laminating a plurality of frame filler bottom plies at intervals along the laminate surface to define a plurality of frame filler positions. The method involves at least one frame filler inner ply over one or more protrusions of the frame filler bottom ply so that at least one overlap of the frame filler bottom plies is not covered by the frame filler inner ply. Includes stacking. Further, the method comprises stacking at least one stringer body ply so as to define a stringer body portion that extends along the stacking surface and overlaps the overlapping portion at one or more of the frame filler positions. The method involves at least one or more frame filler positions such that at least one frame filler inner ply at at least one frame filler position is captured between the frame filler bottom ply and the frame filler top ply. It further comprises stacking the frame filler upper ply on top of one frame filler inner ply.

The features, functions, and advantages described above can be achieved alone in the various embodiments of the present disclosure, or can be combined in yet another embodiment, the further details of which are described below and in the drawings. Can be confirmed by referring to.

These and other features of the present disclosure are made clear by reference to the drawings, and similar reference numbers throughout refer to similar parts.

It is a top view of an Example of a manufacturing system for laying up a composite laminated board (for example, a stringer laminated board) having an integral frame filler. It is a side view of the manufacturing system cut out along the line 2-2 of FIG. An enlarged top view of the circled area identified by reference numeral 3 in FIG. 1, supported on a laminating table for laying up (eg, laminating) composite plies and having an integral frame filler. A plurality of laminated heads for producing stringer laminated plates are illustrated. A side view of the manufacturing system cut along line 4-4 of FIG. 3, end-to-end connected on a stacking table moving from right to left during stacking of stringer laminates. A plurality of laminated heads in an arrangement are illustrated. FIG. 3 is a cross-sectional view of a manufacturing system cut along line 5-5 of FIG. 3, exemplifying a laminated head supported by a cross beam with both ends attached to a pair of vertical posts. It is a side view of one Example of the laminated head cut out along the line 6-6 of FIG. FIG. 5 is a perspective view of an embodiment of a frame filler outer ply laminate head as one of a plurality of laminate heads for laying up a stringer laminate, wherein the frame filler outer ply laminate heads are spaced along a laminate table. The frame filler bottom plies are laminated with a gap to define multiple frame filler positions. It is a cross-sectional view cut along the line 8-8 of FIG. 7, and illustrates the frame filler bottom ply supported on the laminated table. FIG. 5 is a perspective view of an embodiment of a first frame filler inner ply laminate head as an addition to a plurality of laminate heads for laying up a stringer laminate, wherein the first frame filler inner ply laminate head is , The first frame filler inner ply is laminated on the protruding portion of the frame filler bottom ply at each frame filler position. FIG. 9 is a cross-sectional view cut along line 10-10 of FIG. 9 exemplifying a first frame filler inner ply laid up over a frame filler bottom ply. FIG. 5 is a perspective view of an embodiment of a second frame filler inner ply laminate head as an addition to a plurality of laminate heads for laying up a stringer laminate, wherein the second frame filler inner ply laminate head is , The second frame filler inner ply is laminated on the first frame filler inner ply at each frame filler position. FIG. 5 is a cross-sectional view taken along line 12-12 of FIG. 11 exemplifying a second frame filler inner ply laid up on top of a first frame filler inner ply. FIG. 5 is a perspective view of an embodiment of a third frame filler inner ply laminate head as an addition to a plurality of laminate heads for laying up stringer laminates, wherein the third frame filler inner ply laminate head is , The third frame filler inner ply is laminated on the second frame filler inner ply at each frame filler position. FIG. 6 is a cross-sectional view taken along line 14-14 of FIG. 13 exemplifying a third frame filler inner ply laid up on top of a second frame filler inner ply. FIG. 5 is a perspective view of an embodiment of a first stringer body ply laminate head as an addition to a plurality of laminate heads for laying up a stringer laminate, wherein the first stringer body ply laminate head is laminated. A first stringer body ply that extends continuously along the surface and overlaps the overlapping portion of the frame filler bottom ply at each frame filler position is laminated. FIG. 5 is a cross-sectional view cut along line 16-16 of FIG. 15 exemplifying a first stringer body ply laid up over an overlapping portion of the frame filler bottom ply. FIG. 5 is a perspective view of an embodiment of a second stringer body ply laminate head as an addition to a plurality of laminate heads for laying up a stringer laminate, wherein the second stringer body ply laminate head is a first. A second stringer body ply that extends continuously on the stringer body ply of 1 is laminated. FIG. 6 is a cross-sectional view taken along line 18-18 of FIG. 17 exemplifying a second stringer body ply laid up on top of a first stringer body ply. FIG. 3 is a perspective view of an embodiment of a third stringer body ply laminate head as an addition to a plurality of laminate heads for laying up a stringer laminate, wherein the third stringer body ply laminate head is a first. A third stringer body ply extending continuously on the second stringer body ply is laminated. FIG. 5 is a cross-sectional view taken along line 20-20 of FIG. 19 exemplifying a third stringer body ply laid up on top of a second stringer body ply. FIG. 5 is a perspective view of an embodiment of a frame filler outer ply laminated head in which a frame filler upper ply is laid up on a third frame filler inner ply and a stringer main body portion at each frame filler position. FIG. 2 is a cross-sectional view taken along line 22-22 of FIG. 21, exemplifying a frame filler upper ply that is laid up over a third frame filler inner ply and extends over the width of the third stringer body ply. To do. It is a perspective view of an Example of the stringer laminated plate which has a stringer main body part and a plurality of frame filler parts protruding sideways from one of the stringer body side edges of a stringer main body part. It is an exploded perspective view of the stringer laminated plate of FIG. 23. It is a top view of the example of the stringer laminated board of FIG. It is a cross-sectional view cut along the line 26-26 of FIG. 25, exemplifies the stringer body ply constituting the stringer body part, and further illustrates the side edges of the stringer body on both sides formed as oblique edges, respectively. It is sectional drawing of the stringer laminated plate cut out along the line 27-27 of FIG. The arrangement stringer body ply is illustrated, and the frame filler inner ply trapped between the frame filler bottom ply and the frame filler top ply is further illustrated. FIG. 5 is a cross-sectional view taken along line 28-28 of FIG. 25, exemplifying both edge edges of a frame filler bottom ply, a frame filler inner ply, and a frame filler top ply that define an oblique edge. FIG. 5 is a perspective view of an embodiment of a molded stringer having a trapezoidal cross-sectional shape after molding and curing a stringer laminated plate having a frame filler portion protruding from one of the side edges of the stringer body portion of the stringer body portion. It is sectional drawing of the molded stringer cut out along the line 30-30 of FIG. 29, and exemplifies the flange portions on both sides of the molded stringer having the side edges of the stringer body on both sides formed as oblique edges, respectively. It is sectional drawing of the molded stringer cut out along the line 31-31 of FIG. 29, and illustrates the frame filler portion protruding from the flange portion on one side of the molded stringer. FIG. 5 is a perspective view of an embodiment of a composite structure having an outer panel to which a plurality of molded stringers are assembled. Each of the plurality of molded stringers has a frame filler portion protruding from one of the side edges of the stringer body. FIG. 5 is a perspective view of an embodiment of a composite structure configured as a panel assembly having a plurality of molded stringers connected to an outer panel, further illustrating a pair of frames for connection to the composite structure. The frontmost frame is shown to be connected to the joint surface collectively defined by the flange portion and frame filler portion of the stringer laminate, and the rearmost frame is the frame filler portion and flange. It is shown to be separated from the joint surface defined by the portion. FIG. 3 is a cross-sectional view of a composite structure cut along lines 34-34 of FIG. 33, illustrating a frame flange of a frame attached to a joint surface collectively defined by a flange portion and a frame filler portion to illustrate a frame. Further exemplifying a mechanical fastener that connects a flange to a skin panel. FIG. 6 is a cross-sectional view of a composite structure cut along lines 35-35 of FIG. 34, exemplifying a frame flange of a frame that is supported on a frame filler portion and mechanically fixed to an outer panel. It is an enlarged view of the area surrounded by the circle specified by the reference number 36 of FIG. 34, and is a frame filler of one of the molded stringers extending to the side edge of the stringer body of the adjacent molded stringers over the outer panel. Frames and mechanical fasteners have been excluded to clearly illustrate the parts. Of an example of a composite structure configured as a fuselage barrel portion having a plurality of preformed stringers generally oriented in the longitudinal direction and a plurality of axially spaced outer peripheral frames covered by outer skin panels. It is a perspective view. The outer skin panel extends 360 degrees around the molded stringer and outer frame. FIG. 3 is an enlarged view of a circled region of the fuselage barrel portion identified by reference numeral 38 in FIG. 37, exemplifying an outer peripheral frame mechanically fixed to a flange portion and a frame filler portion of a molded stringer. Further stringer laminates with frame filler outer plies laid up to be laminated on the outside of one of the frame filler bottom plies to accommodate differences in the thickness of the flange portions of adjacent molded stringers. It is an exploded perspective view of an Example. It is sectional drawing of the stringer laminated body cut along the line 40-40 of FIG. 39, and illustrates the frame filler outer ply located below the frame filler bottom ply. FIG. 3 is a perspective view of an embodiment of a molded stringer after molding and curing a stringer laminate having the same configuration as in FIGS. 39 and 40, wherein a frame filler external ply is placed on one of the frame filler portions. Further illustrated. It is a top view of an Example of a stringer laminated plate which has a frame filler part protruding from each of the side edges of a stringer body on both sides of a stringer body part. It is sectional drawing of the stringer laminated plate cut out along the line 43-43 of FIG. 42, is arranged side by side with the corresponding ply of the frame filler inner plies on both sides of a stringer body part, and both sides of a stringer body part. Illustrates a stringer body ply that defines a slope corner that complements the beveled edge of. It is a perspective view of an Example of a molded stringer after molding and curing a stringer laminated board having a frame filler portion protruding from each of the side edges of the stringer main body on both sides. FIG. 5 is a perspective view of an embodiment of a composite structure configured as a panel assembly having a plurality of molded stringers connected to an outer panel, and has a frame filler portion protruding from each of the side edges of the stringer body on both sides. Indicates one of the completed stringers. In a perspective view of an embodiment of a manufacturing system in which one of the frame filler laminate heads is configured as a dual spindle laminate head for simultaneously stacking pairs of frame filler inner plies that are separated and parallel to each other. is there. FIG. 6 is a cross-sectional view taken along line 47-47 of FIG. 46, exemplifying a spaced pair of frame filler inner plies formed on top of the frame filler bottom ply. FIG. 5 is a top view of an embodiment of a manufacturing system having a continuous loop laminated belt that is movable below a plurality of laminated heads in a stationary state. It is a side view of the manufacturing system cut along line 49-49 of FIG. 48, exemplifying a stringer laminate supported on a laminate belt that is movable below a plurality of laminate heads. It is sectional drawing of the manufacturing system which illustrates the laminated head configured as a dual spindle type laminated head. FIG. 5 is a top view of an embodiment of a manufacturing system having a plurality of laminated heads configured to move over a laminated surface during the production of a stationary laminated surface and a stringer laminated plate. It is a side view of the manufacturing system cut out along the line 52-52 of FIG. It is sectional drawing of the manufacturing system cut out along the line 53-53 of FIG. It is a flow diagram which includes the process of the method of laying up a stringer laminated board.

In the following, reference is made to drawings illustrating various embodiments of the present disclosure. In FIG. 1, in order to lay up an uncured composite laminated board 298 (for example, a stringer laminated board 300) provided with an integrated extending portion 398 (for example, a frame filler portion 340) integrated with the composite laminated board 298. A top view of an embodiment of the manufacturing system 100 of the above is shown. FIG. 2 is a side view of the manufacturing system 100 of FIG. The embodiments of the present disclosure of the manufacturing system 100 relate to laying up a stringer laminate 300 (eg, FIG. 23) having an integrated frame filler portion 340 (ie, an integral extension portion 398). Explained. The stringer laminate 300 can be formed on a molded stringer 400 (eg, FIG. 29) having a desired cross-sectional shape.

The stringer laminate 300 represents one of a variety of composite laminates 298 that can be laid up using the manufacturing system 100 of the present disclosure. In one mounting embodiment, the stringer laminate 300 can be formed on the molded stringer 400 having a desired cross-sectional profile, and a plurality of molded stringer 400s are assembled together with the outer panel to reinforce the outer panel. Can be cured or co-bonded. In one embodiment, a plurality of preformed stringers 400 may be positioned on a rotatable layup mandrel (not shown) and an outer skin panel 456 (FIG. 37-38) may be located on the preformed stringers 400 and Can be laid up on top of the layup mandrel. The outer skin panel 456 and the molded stringer 400 can be co-cured, and a bonded structure such as the outer frame 420 (eg, FIGS. 37-38) of the skin panel 456, as described in more detail below It can be mechanically fixed to the inner surface to form a fuselage barrel portion 452 (eg, FIGS. 37-38). The frame filler portion 340 of the stringer laminate 300 fills the above-mentioned gap (not shown) existing between the outer peripheral frame 420 and the inner surface of the outer panel 456.

Advantageously, as compared with the laborious and time-consuming conventional method of filling the gap between the frame 420 and the outer panel 456 by integrating the frame filler portion 340 with the stringer laminate 300. , A significant improvement is possible in the assembly of the barrel portion 452. For example, in one such conventional method, a composite ply is cut into strips of unique shape, the strips are folded along a specified fold line, and a frame filler having the appropriate length, width, and thickness. It was accompanied by the manual production of individual frame fillers (not shown) by making. Once the cutting and folding process is complete, each frame filler must be manually placed in the appropriate position on the layup mandrel (not shown) before laying up the skin panel. Additional composite ply patches (not shown) may be required at specific locations on the fuselage barrel to accommodate differences in the thickness of adjacent stringer flanges. Such ply patches also need to be manually cut out of the composite and mounted in place on the layup mandrel. Manually cutting, folding, and installing individual frame fillers at multiple locations on the fuselage barrel is a laborious and / or costly process that significantly impacts production rates.

Another conventional method of producing frame fillers is to lay up each stringer laminate (not shown) with a width that accommodates the width of the bay between adjacent molded stringers (eg, FIG. 37). Accompany. Once the stringer laminate layup is complete, the stringer laminate is trimmed from at least one of the sides of the stringer laminate at a position along the length of the stringer where each outer frame is sequentially installed. A protruding tab out (ie, a frame filler) is created. Trimming each stringer laminate to create multiple protruding tabs along the length of the stringer significantly increases the stringer production time. In addition, the presence of a portion of the trimmed stringer laminate indicates a relatively large amount of unused composite material, increasing the total cost of stringer production.

Advantageously, the embodiments of the present disclosure of the manufacturing system 100 are timely and cost-effectively methods for a composite laminate 298 with an integrated extension 398 (FIG. 1) (eg, FIG. 1-2). ) Allows you to lay up any one of a variety of different configurations. As described above, the embodiment of the manufacturing system 100 is not limited to laying up the stringer laminate 300 having the frame filler portion 340 in order to continuously form a composite stringer (FIG. 29).

In the embodiment of FIGS. 1 to 2, the manufacturing system 100 stacks the frame filler portions 340 (FIG. 23) at each of the plurality of frame filler positions 342 separated along the length of the stringer main body portion 320. A plurality of laminated heads configured to lay up the composite ply 302 (for example, FIGS. 7 to 22) of the stringer main body portion 320 (FIG. 23) of the stringer laminated plate 300 while simultaneously laying up the composite ply 302. Includes 200. Advantageously, the manufacturing system 100 and method 500 of the present disclosure (FIG. 54) avoid the need for laborious and separate steps of making composite stringers and making individual frame fillers. Further, the manufacturing system 100 and method 500 of the present disclosure avoid the time consuming process of positioning individual frame fillers (not shown) at the frame mounting positions of the composite structure 450 (eg, FIG. 37). As a result, the stringer laminate 300 made using the manufacturing system 100 and method 500 of the present disclosure results in a reduction in the total amount of parts that must be assembled to make the composite structure 450, by the composite stringer. It is possible to improve the production throughput of the production of the reinforced composite structure 450.

Referring to FIGS. 1 to 4, the manufacturing system 100 includes a stacking surface 120 and a plurality of stacking heads 200. The laminated head 200 is a composite ply of composite material 238 along the distribution direction 254 (FIG. 6) during relative motion between the laminated surface 120 and the laminated head 200 along a direction generally aligned with the distribution direction 254. 302 (eg, FIGS. 7 to 22) is configured to lay up on the laminated surface 120 and / or the composite ply 302 added earlier. The stacking head 200 may be configured to lay up the composite ply 302 along the distribution direction 254. The plurality of laminated heads 200 include at least one frame filler outer ply laminated head 202 (for example, FIGS. 7 and 21) and at least one frame filler inner ply laminated head 204 (for example, FIGS. 9, 11, and 13). , And at least one stringer body stacking head 210 (eg, FIGS. 15, 17, and 19).

In the embodiments shown in FIGS. 1 to 4, the manufacturing system 100 includes a frame filler outer ply laminating head 202 (FIG. 7) for laminating the frame filler bottom ply 350 at each frame filler position 342. An exemplary manufacturing system 100 includes three frame filler inner ply stacking heads 204, 206, 208 offset laterally from the stringer body ply stacking heads 210, 212, 214 (FIGS. 15, 17, 19). 9, FIG. 11 and FIG. 13) are further provided. The frame filler inner ply laminated heads 204, 206, 208 respectively have the frame filler inner ply 355 placed on the frame filler bottom ply 350 or on the previously added frame filler inner ply 355 at each frame filler position 342. It is configured to be laminated. As described in more detail below, the frame filler inner plies 355 are laid up in a stacked manner at each frame filler position 342. While the exemplary manufacturing system 100 of the present disclosure has three frame filler inner ply stacking heads, another embodiment of the manufacturing system 100 stacks the corresponding quantity of frame filler inner plies 355 at each frame filler position 342. Any number of frame filler inner ply laminated heads may be included to do so.

In the illustrated embodiment, the manufacturing system 100 has three stringer body ply stacking heads 210, 212, 214 offset laterally from the frame filler inner ply stacking heads 204, 206, 208 as described above (FIG. 15, FIG. 15, 17 and 19) are further included. The stringer body ply stacking heads 210, 212, 214 can be configured to lay up the stringer body ply 325 (FIGS. 15, 17, 19), respectively. Each stringer body ply 325 extends along the stacking surface 120 and overlaps the frame filler bottom ply 350 located at each frame filler position 342 or overlaps with the previously added stringer body ply 325. As will be described in more detail below, the stringer body ply 325 will have an overlapping shape and collectively define the stringer body portion 320 of the stringer laminate 300. Each stringer body ply 325 is arranged side by side with the frame filler inner ply 355 (FIG. 22). In some embodiments, the quantity of stringer body ply stacking heads 210, 212, 214 is such that the quantity of stringer body ply 325 is equal to the quantity of frame filler inner ply stacking heads 204, 206. , 208 may be equal to the quantity. The embodiment of the manufacturing system 100 of the present disclosure has three stringer body ply laminated heads, while other examples of the manufacturing system 100 may include any number of stringer body ply laminated heads.

In the embodiments shown in FIGS. 1 to 4, the manufacturing system 100 includes a frame filler outer ply laminating head 202 (FIG. 21) for laminating the frame filler upper ply 348 at each frame filler position 342. Alternatively, the frame filler outer ply laminated head 202 used for the layup of the frame filler bottom ply 350 may be used for the layup of the frame filler top ply 348. The frame filler upper ply 348 extends at each frame filler position 342 over the combined width of the stringer body portion 320 and the frame filler inner ply 355. The frame filler inner ply 355 at each frame filler position 342 is trapped between the frame filler bottom ply 350 and the frame filler top ply 348 so that the uncured stringer laminate 300 is at least one of the stringer body portions 320. It has a plurality of frame filler portions 340 protruding laterally from one stringer body side edge 324. The frame filler bottom ply 350, frame filler inner ply 355, stringer body ply 325, and frame filler top ply 348 can all be formed from composite material 238 of constant width, whereby the stringer laminate after layup is complete. Eliminates the need to trim the 300.

In FIGS. 1 to 4, the stacking head 200 is stationary and defines the stacking station 198 of the manufacturing system 100. The plurality of laminated heads 200 may be supported by the support frame 104 and positioned end-to-end relation with each other to define a series of laminated heads 200. Although the plurality of laminated heads 200 are shown to be uniformly separated from each other, the plurality of laminated heads 200 may be unevenly separated from each other. Although the plurality of laminated heads 200 are shown to be close to each other, they may be arranged so that there is a gap between the plurality of laminated heads 200. The frame filler bottom ply 350 (FIG. 7), the frame filler inner ply 355 (FIGS. 9 to 14), the stringer body ply 325 (FIGS. 15 to 20), and the frame filler top ply 348 (FIGS. 21 to 22) are sequentially arranged. A series of stacking heads 200 can be arranged to lay up, whereby the stringer body portion 320 and the frame filler portion 340 are laminated in a desired ply stacking sequence defined by the position of the stacking heads 200 relative to each other. .. Although the series of laminated heads 200 are shown in a linear arrangement, the laminated heads 200 may be arranged non-linearly (for example, in an arc shape (not shown)). Therefore, the distribution direction 254, which is collectively defined by the plurality of laminated heads 200 being continuous from end to end, may be linear or non-linear.

In FIGS. 1 to 4, the laminate surface 120 is configured to move below the laminate head 200 during the layup of the stringer laminate 300 along a direction generally aligned with the distribution direction 254 (FIG. 6). ing. The stacking heads 200 of FIGS. 1 to 4 are immovable along at least the length direction of the manufacturing system 100, whereas any one or more stacking heads 200 (orthogonal to the length direction). It may be movable along the transverse direction. Further, any one or more stacking heads 200 may be movable perpendicular to the stacking surface 120, as described in more detail below.

In FIGS. 1 to 4, the laminated surface 120 includes an outer surface or an upper surface of a stationary rigid laminated table 122 supported on a base member 102 of the manufacturing system 100. The stacking table 122 can be a generally rigid structure that can move below the stacking head 200 along a direction parallel to the distribution direction 254. The stacking table 122 may be supported on longitudinal rails 124 extending along the length direction of the base member 102. The manufacturing system 100 may include a linear actuation mechanism (not shown) such as a screwdriver connected to a drive motor for moving the stacking table 122 along the longitudinal rail 124.

In FIGS. 1 and 2, the stacking table 122 is movable from the stacking surface home position 130 and may pass through the stacking station 198 before reaching the stacking surface rear position 132. In some embodiments, when the stacking table 122 passes through the stacking station 198 once, the stacking table 122 may be restricted to unidirectional movement to lay up the stringer laminate 300. However, in another embodiment, the stacking table 122 may be configured to move back and forth below the stacking head 200 in order to lay up the stringer stacking plate 300. For example, the stacking table 122 may pass through the stacking station 198 twice in both directions to lay up the stringer laminate 300. After the layup of the stringer laminate 300 is complete, the laminate table 122 may be movable to the laminate surface offloading position (not shown).

With reference to FIGS. 5 and 6, FIG. 5 shows a cross-sectional view of the manufacturing system 100 showing the stacking head 200 in a stationary state with respect to the stacking table 122. The stacking table 122 is shown to be supported on longitudinal rails 124 attached to the base member 102. Each laminated head 200 may be supported by the support frame 104 described above. The support frame 104 may include a cross beam 108 with both ends attached to a pair of vertical posts 106 extending upward from the base member 102. To position the plurality of stacked heads 200 laterally to each other, the stacked heads 200 move horizontally (eg, laterally) along the crossbeam 108 via a linear actuation mechanism (not shown). It can be possible. The laminated head 200 can be independently moved laterally along the cross beam 108, whereby the laminated head 200 can be positioned laterally, and the stringer main body portion 320 and the frame filler portion 340 (FIG. 1) can be positioned laterally. Therefore it may be possible to lay up one of the various configurations of the stringer laminate 300 with varying width requirements.

In addition to lateral motion capability along the crossbeam 108, each laminated head 200 may be vertically movable to accommodate the start and stop of distribution of the layup material 236 from the laminated head 200. For example, both ends of the crossbeam 108 may be vertically movable with respect to the post 106 via a linear actuation mechanism (not shown). In any of the embodiments disclosed herein (eg, FIGS. 1 to 21 and 48 to 53), the motion of the stacking surface 120 (eg, stacking table 122), the motion of the stacking head 200 (eg,). , Motion along length, lateral positioning, vertical motion), and the actions of the components described below for each stacked head 200 execute measurable and readable program commands (eg, numerical control programs). It can be controlled by controller 116 (FIG. 5). For example, in the manufacturing system 100 shown in FIGS. 1 to 21, the controller 116 controls the movement along the length of the stacking table 122 with respect to the stacking head 200, while laterally positioning and vertically moving the stacking head 200 in a stationary state. Can be controlled. In the exemplary manufacturing system 100 shown in FIGS. 48-50, the controller 116 can control the lateral positioning and vertical movement of the stationary stacking head 200 with respect to the movable stacking belt 126. In the exemplary manufacturing system 100 shown in FIGS. 51 to 53, the controller 116 controls the movement of the stacking head 200 along the length, and further positions the stacking head 200 laterally with respect to the stationary stacking surface 120. Vertical movement can be controlled.

FIG. 6 is a side view of an embodiment of the laminated head 200. Each laminated head 200 is configured to distribute the layup material 236 (eg, composite material 238) along the distribution direction 254. The components of the stacking head 200 may be attached to a mounting frame 230 that may be connected to a cross beam (eg, FIG. 5) or gantry 110 (eg, FIG. 53) of the support frame 104. In the illustrated embodiment, the laminate head 200 may include at least one material feeding drum 232 configured to support the material roll 234 of the layup material 236. The layup material 236 may be a lined material 240 or an unlined material (not shown). The backed material 240 may be lined by a backing layer 242. The lining layer 242 prevents the layup material 236 from adhering to the adjacent rolled layup material 236 on the material roll 234.

As mentioned above, the layup material 236 can be a composite material 238 for laying up (ie, laminating) the composite ply 302 in order to form the stringer laminate 300 (FIG. 1). The composite material 238 may be a pre-impregnated fiber-reinforced polymer material or resin, or the composite material 238 has been laminated with the stringer laminate 300, and the stringer laminate 300 has been formed into a desired cross-sectional shape. After that, it may be a dry fiber material into which a resin (for example, a polymer material) is injected. The resin or polymer material may be a thermosetting resin or a thermoplastic resin. The fiber may be glass fiber (eg, fiberglass), carbon fiber, Kevlar fiber, boron fiber, aramid fiber, metal fiber, ceramic fiber, and / or other fiber material. Composite material 238 may be provided in one-way tape, cloth, fabric, or other composition. In addition to distributing the composite material 238, the laminate head 200 may be further configured to distribute the non-composite material (eg, metal leaf or metal mesh) during the layup of the stringer laminate 300. The layup material 236 may further include a processing material used in the processing of the stringer laminate 300. Such treatment materials can facilitate laminating, forming, strengthening, debulking, and / or curing the stringer laminate 300, or the stringer laminate 300 and other composite components (eg, skin panels). It can facilitate joining and / or assembling with 456 (FIG. 32)) or non-composite structures (not shown).

For example, before laying up the stringer laminate 300, one or more of the laminate heads (not shown) may be configured to distribute a protective material (eg, peel ply) to the laminate surface 120. This protective material functions as a protective layer 306 (FIGS. 7 and 8) to prevent contamination of the surface of the stringer laminate 300 and is a composite component separate from the molded stringer (eg, FIG. 32) (eg, outside of the above description). It facilitates joining with the plate panel 456). Upon completion of the layup of the composite ply 302 of the stringer laminate 300, the laminate head (not shown) provides a protective layer (not shown) on top of the stringer laminate 300 for subsequent handling of the stringer laminate 300 (not shown). For example, the stringer laminate 300 may be further configured to prevent contamination between preformed stringers 400 of the desired cross-sectional shape (eg, FIG. 29). In another embodiment, one or more of the laminate heads 200 may be used to improve adhesion between the stringer laminate 300 and the laminate surface 120 and / or assemble the stringer laminate 300 and other composite parts. It is configured to distribute an adhesive material (eg, an adhesive film (not shown)) for laying up (eg, laminating) the adhesive layer on one or both sides of the stringer laminate 300 to facilitate. In yet another embodiment, one or more of the laminate heads 200 are with the stringer laminate 300 and another surface (eg, a molded mandrel (not shown) and / or a cured mandrel (not shown)). In order to prevent adhesion, a release material (for example, fluorinated ethylene propylene) for laying up (for example, laminating) the release layer may be distributed on one or both sides of the stringer laminate 300.

Further referring to FIG. 6, the laminated head 200 may include one or more reorienting rollers 244 for guiding the layup material 236 through the components of the laminated head 200. At each frame filler position 342, the laminated head 200 includes a frame filler bottom ply (eg, FIG. 7), a frame filler inner ply (eg, FIGS. 9, 11, and 13), and a frame filler top ply (eg, FIG. A cutter assembly 246 for cutting the layup material 236 may be further included while the distribution of the layup material 236 is started and stopped, such as when laying up 15, FIG. 17 and FIG. 19). For a backed material 240, such as composite 238, the cutter assembly 246 may be configured to cut the composite 238 without damaging the backing layer 242. The stacking head 200 adds a layup material 236 onto the stacking surface 120 or onto a previously added layup material 236 and compresses a compression device 250 (eg, a compression roller or compression shoe). May include. Further, the laminated head 200 has a backing layer separator 248 for separating the layup material 236 from the backing layer 242, and a backing layer recovery drum 252 configured to take in the backing layer 242 after being separated from the layup material 236. May include.

Referring to FIGS. 7 to 22, the frame filler outer ply laminate head 202 (FIGS. 7 and 21) and the frame filler inner ply laminate heads 204 and 206 for laminating the stringer laminates 300 (FIGS. 21 and 22). , 208 (FIGS. 9, 11, and 13), and stringer body ply stacking heads 210, 212, 214 (FIGS. 15, 17, and 19) show a continuous layup of composite plies 302. .. As described above, the embodiment of the manufacturing system 100 of the present disclosure is an uncured composite laminate 298 (eg, frame filler portion 340) provided with an integral extension 398 (eg, frame filler portion 340) that is integral with the composite laminate 298. For example, it is configured to lay up a stringer laminate 300). 7 to 22 lay up the stringer laminate 300 as an embodiment of any one of the various configurations of the composite laminate 298 (FIGS. 1 and 2) that can be laid up by the manufacturing system 100. Illustrate that. Therefore, the laminated head 200 of FIGS. 7 to 22 is configured to lay up a composite laminated board 298 configured as a stringer laminated board 300 having an integrated frame filler portion 340. The frame filler outer ply laminated head 202 may be described as an integrated extended outer ply laminated head. Similarly, the frame filler inner ply laminate heads 204, 206, 208 may be described as an integrated extended inner ply laminate head. The stringer main body ply laminated heads 210, 212, and 214 may be described as laminated plate main body ply laminated heads.

FIG. 7 shows an embodiment of the frame filler outer ply laminating head 202 that lays up the frame filler bottom ply 350 at each frame filler position 342 separated along the laminating table 122. In the illustrated embodiment, the stacking table 122 may be movable relative to the stacking head 200, which may be stationary. However, the manufacturing system 100 may include a stacking head 200 that is movable with respect to the stationary stacking surface 120, as in the later embodiments shown in FIGS. 51-53. FIG. 8 is a schematic cross-sectional view of a manufacturing system 100 showing a frame filler bottom ply 350 supported by a protective layer 306 on a laminated table 122 by cutting out one of the frame filler positions 342 of FIG. The frame filler outer ply laminating head 202 may be configured to distribute the composite material 238 for laminating each frame filler bottom ply 350 with a common width. The frame filler bottom ply 350 may be laid up directly on the laminated surface 120 (eg, the laminated table 122). Alternatively, the frame filler bottom ply 350 may be laid up on the treated layer 304 previously applied to the laminated surface 120 by a treated material laminate head (not shown). As described above, the protective layer 306 can prevent contamination of the bottom surface of the stringer laminated board 300. Further, the resin in the composite material 238 of the stringer laminated board 300 can be lightly adhered to the protective layer 306 to prevent the stringer laminated board 300 from shifting during the layup process. In any of the embodiments of the manufacturing system 100 of the present disclosure, the laminate surface 120 optionally draws vacuum pressure on the composite ply 302 to prevent movement of the stringer laminate 300 during layup. It may include multiple openings (not shown) connected to a vacuum pressure source (not shown).

With reference to FIGS. 9 to 14, examples of the above-mentioned frame filler inner ply laminated heads 204, 206, 208 for laying up the frame filler inner ply 355 of the stringer laminated plate 300 are shown. FIG. 9 is a perspective view of the manufacturing system 100 so that the overlapping portion 354 (FIG. 24) of each frame filler bottom ply 350 is not covered by the first frame filler inner ply 356 at each frame filler position 342. A first frame filler inner ply stacking head 204 for laying up the first frame filler inner ply 356 is shown above the protrusion 352 (FIG. 24) of the frame filler bottom ply 350 at each frame filler position 342. Immediately after the frame filler bottom ply 350 is laid up on the laminated table 122, the first frame filler inner ply 356 may be laid up on the frame filler bottom ply 350 at each frame filler position 342. FIG. 10 is a schematic cross-sectional view of the manufacturing system 100 showing the first frame filler inner ply 356 cut out of the frame filler position 342 of FIG. 9 and laid up on the frame filler bottom ply 350. In FIG. 9, the first frame filler inner ply laminate head 204 may be offset laterally from the frame filler outer ply laminate head 202. Further, in the first frame filler inner ply laminated head 204, as will be described later, the frame filler inner ply covers only the protruding portion 352 of the frame filler bottom ply 350, and the first stringer body ply 326 (FIG. 15) Distribute composite material 238 having a width narrower than the width of composite material 238 distributed by the frame filler outer ply laminate head 202 so that the overlap portion 354 remains temporarily exposed prior to layup. Can be configured as

FIG. 11 is a perspective view of a manufacturing system 100 showing a second frame filler inner ply laminate head 206 as one of the additions to the plurality of laminate heads 200 for laying up the stringer laminate 300. In the manufacturing system 100, immediately after the layup of the first frame filler inner ply 356 by the first frame filler inner ply laminated head 204, the second frame filler inner ply laminated head 206 is placed at each frame filler position 342. The second frame filler inner ply 358 may be configured to lay up on top of the first frame filler inner ply 356. FIG. 12 is a schematic cross-sectional view of the manufacturing system 100 showing the second frame filler inner ply 358 cut out of the frame filler position 342 of FIG. 11 and laid up on the first frame filler inner ply 356. In some embodiments, it is distributed by a second frame filler inner ply stacking head 206 as a means of creating an oblique edge 382 (FIG. 14) on at least one frame filler side edge 346 (FIG. 14) of the frame filler portion 340. The composite material 238 may have a narrower width than the composite material 238 distributed by the first frame filler inner ply stacking head 204. As will be described later, the stringer body ply 325 (FIG. 22) is also laid up with a gradually narrowing width so that an oblique edge 382 that complements the oblique edge 382 of the frame filler inner ply 355 can be obtained as a result. Can be up.

FIG. 13 is a perspective view of a manufacturing system 100 showing a third frame filler inner ply laminate head 208 as one of the additions to the plurality of laminate heads 200 for laying up the stringer laminate 300. The third frame filler inner ply stacking head 208 is configured to lay up the third frame filler inner ply 360 on top of the second frame filler inner ply 358 at each frame filler position 342. Immediately after the layup of the second frame filler inner ply 358, the third frame filler inner ply 360 may be laid up. FIG. 14 is a schematic cross-sectional view of the manufacturing system 100 showing the third frame filler inner ply 360 cut out of the frame filler position 342 of FIG. 13 and laid up on the second frame filler inner ply 358. Similar to the width difference of the composite material 238 described above between the first frame filler inner ply 356 and the second frame filler inner ply 358, the third frame filler inner ply 360 is of the frame filler portion 340. It may have a narrower width than the second frame filler inner ply 358 to create an oblique edge 382 (FIG. 14) on the frame filler side edge 346.

With reference to FIGS. 15 to 20, examples of stringer body ply laminated heads 210, 212, 214 laying up the stringer body ply 325 adjacent to the frame filler inner ply 355 are shown. As described above, the stringer body ply 325 defines the stringer body portion 320. One or more of the stringer body plies 325 may extend continuously along the length of the stringer laminate 300. However, in other embodiments not shown, the stringer laminate 300 may result in one or more of the stringer body plies 325 being discontinuous along the length of the stringer laminate 300. It may include multiple splices or other embodiments (eg, ply drops and / or ply adducts). FIG. 15 is a perspective view of a manufacturing system 100 showing an embodiment of a first stringer body ply laminated head 210 that lays up the first stringer body ply 326 of the stringer body portion 320. The first stringer body ply 326 is shown to extend continuously along the stacking surface 120 and overlap the overlapping portion 354 of the frame filler bottom ply 350 at each frame filler position 342. However, as described above, the first stringer body ply 326 may eventually have one or more such that the first stringer body ply 326 is discontinuous along the length of the stringer laminate 300. May include splices. For example, the first stringer body ply 326 may consist of two or more stringer body ply segments (not shown) whose ends overlap each other. Alternatively or additionally, the first stringer body ply 326 is shorter than the overall length of the stringer laminate 300 so that the first stringer body ply 326 defines a ply drop (not shown) in the stringer laminate 300. Can have a length. The first stringer body ply 326 is shown to be side-by-side (eg, butt-joined) with the first frame filler inner ply 356. However, in other embodiments not shown, the first stringer body ply 326 may overlap a portion of the first frame filler inner ply 356. In FIG. 16, one of the frame filler positions 342 is cut out, and the first stringer body ply 326 is laid up on the overlapping portion 354 of the frame filler bottom ply 350 to form the first frame filler inner ply 356. It is the schematic sectional drawing of the manufacturing system 100 shown in a side-by-side arrangement. The width of the first stringer body ply 326 may be approximately equal to the difference between the width of the frame filler bottom ply 350 and the width of the first frame filler inner ply 356. In some embodiments, the edges of the stringer body ply may abut and non-overlapping the edges of the first frame filler inner ply 356. However, in some embodiments, a relatively small ply gap of 370 (eg, less than 0.030 inch) may be present between the edge of the first stringer body ply 326 and the edge of the frame filler inner ply. Good.

FIG. 17 shows one of the second stringer body ply stacking heads 212 for laying up the second stringer body ply 328, which appears to extend continuously over the first stringer body ply 326. It is a perspective view of the manufacturing system 100 which shows the Example. However, as described above in connection with the first stringer body ply 326, the second stringer body ply 328 may include one or more splices or other embodiments of the second stringer body. The ply 328 can eventually be discontinuous along the length of the stringer laminate 300. FIG. 18 is a schematic cross-sectional view of the manufacturing system 100 showing a second stringer body ply 328 cut out of one of the frame filler positions 342 and laid up on top of the first stringer body ply 326. As a means of creating an oblique edge 382 in the stringer body ply 325 that complements the slope angle 380 (FIG. 22) of the frame filler inner ply 355, the composite material 238 distributed by the second stringer body ply stacking head 212 is It may have a width greater than the composite material 238 distributed by the stringer body ply stacking head 210 of 1. In addition, the second stringer body ply 328 may have a width that results in the stringer body side edge 324 having an oblique edge 382 (FIG. 22). Similar to the above arrangement shown in FIG. 16, the second stringer body ply 328 of FIG. 18 may be arranged side by side with the second frame filler inner ply 358 so as to minimize the ply gap 370.

FIG. 19 shows one of the third stringer body ply stacking heads 214 for laying up the third stringer body ply 330, which appears to extend continuously over the second stringer body ply 328. It is a perspective view of the manufacturing system 100 which shows the Example. However, as described above with respect to the first stringer body ply 326 and the second stringer body ply 328, the third stringer body ply 330 is optionally non-aligned along the length of the stringer laminate 300. It can be continuous. FIG. 20 is a schematic cross-sectional view of the manufacturing system 100 showing a third stringer body ply 330 cut out of one of the frame filler positions 342 and laid up on top of the second stringer body ply 328. Similar to the above arrangement shown in FIGS. 15-18, the composite distributed by the third stringer body ply stacking head 214 to create an angled edge 382 that complements the slope angle 380 of the frame filler inner ply 355. The material 238 may have a wider width than the composite material 238 distributed by the second stringer body ply stacking head 212.

FIG. 21 is a manufacturing system showing an embodiment of a frame filler outer ply laminated head 202 that lays up a frame filler upper ply 348 on a third frame filler inner ply 360 and a stringer body portion 320 at each frame filler position 342. It is a perspective view of 100. FIG. 22 is a schematic cross-sectional view of the manufacturing system 100 showing a frame filler upper ply 348 cut out of one of the frame filler positions 342 and laid up on a third frame filler inner ply 360. At each frame filler position 342, each of the first, second, and third frame filler inner plies 356, 358, 360 is captured between the frame filler bottom ply 350 and the frame filler top ply 348. The frame filler upper ply 348 at the frame filler position 342 extends over the combined width of the third stringer body ply 330 and the third frame filler inner ply 360. Although not shown in FIG. 22, the frame filler top ply 348 and the frame filler bottom ply 350 complement the slope angle 380 of the frame filler inner ply 355 and the stringer body ply 325, respectively (eg, substantially fitted). ) Can be laid up by width. As described above, the first, second, and third stringer body plies 326, 328, and 330 correspond to the first, second, and third frame filler inner plies 356, 358, and 360, respectively. It is arranged side by side with the ply to be used. However, in the stringer laminate 300, the first, second, and / or third stringer body plies 326, 328, 330 have the first, second, and third frame filler inner plies 356, 358, 360. It may be laid up in a configuration that overlaps with our corresponding ply. In an embodiment of the stringer laminate 300 where the stringer body side edge 324 is an oblique edge 382, the frame filler inner ply 355 may be laid up in front of the stringer body ply 325. In another embodiment of the stringer laminate 300 (not shown) where the stringer body side edge 324 is not beveled, the stringer body ply 325 may be laid up before or after the layup of the frame filler inner ply 355. .. In FIG. 22, the frame filler side edge 346 is shown not to have an oblique angle, but as shown in FIG. 36, the frame filler side edge 346 has an oblique edge 382 of the frame filler portion 340 formed separately. Slope angle 380 that complements the slope corner 380 of the stringer body side edge 324 of the adjacent molded stringer 400 so that it is positioned close to the slope edge 382 of the flange portion 406 of the finished stringer 400. May be done. In addition, the stringer laminate 300 of FIG. 22 has an equal number of stringer body plies and frames to provide a consistent surface (eg, constant height) for accepting the bonded structure (eg, FIG. 33). Although it has a filler inner ply, the stringer laminate 300 may be laid up with a configuration (not shown) in which the number of frame filler inner plies is different from the number of stringer body plies. Further, the stringer laminate 300 has a configuration in which the number of frame filler inner plies at an arbitrary frame filler position 342 is different from the number of frame filler inner plies at one or more of the remaining frame filler positions 342 (not shown). It may be laid up.

With reference to FIGS. 23 to 28, examples of the stringer laminated board 300 laid up in the above steps illustrated in FIGS. 7 to 22 are shown. As described above, the stringer laminate 300 is an embodiment of a variety of different composite laminate 298 configurations (FIGS. 1 and 2) that can be laid up by any of the embodiments of the manufacturing system 100 of the present disclosure. Represent. FIG. 23 shows a stringer composed of a stringer body portion 320 and a plurality of frame filler portions 340 protruding laterally from one of the stringer body side edges 324 of the stringer body portion 320 at the corresponding frame filler positions 342. It is a perspective view of the laminated board 300. FIG. 24 shows an exploded perspective view of the stringer laminated plate 300 of FIG. 23. As described above, the frame filler bottom ply 350 includes the protrusion 352 and the overlap portion 354, respectively, the frame filler inner ply 355 is laid up over the protrusion 352, and the stringer body ply 325 is the overlap portion 354. Lay up on. 23 to 28 show the first, second, and third stringer body ply laminated ply heads 210, 212, 214 (FIG. 21) positioned laterally to the frame filler outer ply laminated head 202 (FIG. 21). Formed using FIG. 21), as a result, at each frame filler position 342, the protrusion 352 of the frame filler bottom ply 350 projects from a single side edge of the stringer body side edge 324 of the stringer body portion 320. An example of the stringer laminated board 300 is shown. However, in another embodiment described later (FIGS. 42 and 43), in the stringer body ply laminated heads 210, 212, 214, as a result, the protrusions 352 at each frame filler position 342 are the stringers on both sides of the stringer body portion 320. It may be positioned with respect to the frame filler outer ply laminated head 202 so as to protrude from each of the main body side edges 324.

With reference to FIGS. 25 to 28, FIG. 25 shows a top view of an embodiment of the stringer laminate 300 in which the plurality of frame filler portions 340 project from the stringer body side edge 324 of the stringer body portion 320. .. As described above, the stringer body portion 320 includes a frame filler upper ply 348 at each frame filler position 342, one or more stringer body plies 325 extending along the length direction of the stringer laminate 300, and each frame. It is composed of a frame filler bottom ply 350 at the filler position 342. In some embodiments, the stringer body portion 320 may be formed so that the aspect ratio of length and width is 2 or more. As described above, the stringer body portion 320 has a stringer body edge 322 that defines the length of the stringer body. Further, the stringer body portion 320 has stringer body side edges 324 on both sides defining the width of the stringer body portion 320. Further, as described above, the stringer laminate 300 is composed of a plurality of frame filler upper plies 348, one or more frame filler inner plies 356, and a frame filler bottom ply 350 at each frame filler position 342. Includes frame filler portion 340.

As described above, the stringer body ply laminated heads 210, 212, 214 distribute composite material 238 of various widths, resulting in at least one of the stringer body side edges 324 on both sides having an oblique edge 382. Can be formed as. For example, FIG. 26 is a cross-sectional view of the stringer body portion 320 of FIG. 25, showing both the stringer body side edges 324 on both sides formed as oblique edges 382. FIG. 27 is a cross-sectional view of the stringer laminated board 300 cut out at one of the frame filler positions 342 of FIG. 25. The stringer laminate 300 is shown in an inverted orientation from the stringer laminate 300 of FIG. 22, in which the frame filler bottom ply 350 is at the top of the stringer laminate 300 and the frame filler top ply 348 is at the bottom. is there. The stringer body ply 325 is arranged side by side with the corresponding frame filler inner ply 355. The slope corner 380 of the stringer body side edge 324 complements the slope corner 380 of the frame filler inner ply 355. FIG. 28 is a cross-sectional view cut along the length direction of one of the frame filler portions 340, showing where the frame filler edge edges 344 on both sides of the frame filler ply define the slope corner angle 380. In any of the examples disclosed herein, stress concentration can be reduced by laminating the stringer body portion 320 and / or the frame filler portion 340 having an oblique edge 382. Stress concentration can occur under other circumstances at the skin panel 456 (FIG. 32) or other composite component assembled to the stringer laminate 300.

Referring to FIGS. 29-35, an embodiment of a molded stringer 400 resulting from the formation of a stringer laminate 300 (FIG. 25) manufactured using the manufacturing system 100 and method of the present disclosure. Shown. In the illustrated embodiment, the molded stringer 400 has a trapezoidal cross-sectional shape after molding and curing the stringer laminate 300 in which the frame filler portion 340 protrudes from one of the stringer body side edges 324 of the stringer body portion 320. The stringer laminate 300 can be formed in any of a variety of alternative shapes, including the trapezoidal shape described above, or a circular cross-section, a square cross-section, a triangular cross-section, or any other cross-section. Not limited to.

In FIGS. 29-32, the molded stringer 400 has a pair of flange portions 406 and a pair of web portions 404 interconnected by a cap portion 402. FIG. 30 is a cross-sectional view of the molded stringer 400 cut along the stringer body portion 320. Each of the flange portions 406 of the molded stringer 400 has a stringer body side edge 324 formed as an oblique edge 382. FIG. 31 is a cross-sectional view of the molded stringer 400 cut along one of the frame filler portions 340. The frame filler portion 340 is shown to project from the flange portion 406 on one side of the molded stringer 400. FIG. 32 is a perspective view of an embodiment of a composite structure 450 having an outer panel 456 (eg, cured or uncured) assembled with a plurality of molded stringers 400 (eg, cured or uncured). It is a figure. Each of the plurality of molded stringers 400 has a frame filler portion 340 protruding from one of the stringer body side edges 324. The frame filler portion 340 protruding from each molded stringer 400 extends to the stringer body side edge 324 of the adjacent molded stringer 400. The molded stringer 400 can be co-bonded or co-cured with the skin panel 456. The frame filler portion 340 and the flange portion 406 may be provided with an on-the-plane joint surface 408 to which other structural pairs such as the frame 420 (FIG. 33) can be attached.

For example, FIG. 33 further comprises a pair of frames 420 that are configured as a panel assembly 454 with a plurality of preformed stringers 400 co-bonded or co-cured to the skin panel 456 and may be mechanically secured to the skin panel 456. The composite structure 450 including is shown. Although the outer panel 456 is shown to have a flat shape, the outer panel 456 may have a non-flat shape and the preformed stringer 400 may have a non-flat shape of the outer panel 456. May be formed to complement. For example, each preformed stringer 400 may be subtly curved along the length direction to fit the corresponding curvature of the skin panel 456. Each frame 420 may include a frame web 424 and a frame flange 422 assembled together. However, in other embodiments not shown, the frame web 424 and frame flange 422 may be integrated so that each frame 420 has an integral structure. The frame web 424 and frame flange 422 of each frame 420 may include a stringer notch 426 sized and configured to complement the size and spacing of the preformed stringers 400 on the skin panel 456. In FIG. 33, one of the frames 420 is shown to be attached to the joint surface 408 collectively defined by the flange portion 406 and the frame filler portion 340 of the stringer laminate 300. The remaining frame 420 is shown to be separated from the preformed stringer 400 and the skin panel 456 to show the joint surface 408 collectively defined by the flange portion 406 and the frame filler portion 340.

FIG. 34 is a cross-sectional view of the composite structure 450 of FIG. 33, showing the frame flange 422 of the frame 420 attached to the joint surface 408 defined by the combination of the flange portion 406 and the frame filler portion 340. A mechanical fastener 428 that connects the frame flange 422 to the skin panel 456 is also shown. As shown, the frame filler portion 340 and the flange portion 406 provide a coplanar joint surface 408 for the frame flange 422. FIG. 35 is a cross-sectional view of the composite structure 450, showing the frame flange 422 of the frame 420 supported on the frame filler portion 340 and fixed to the outer panel 456. FIG. 36 shows a molded stringer 400 connected to an outer panel 456. By omitting the frame 420 and the mechanical fastener 428 in FIG. 36, the molded stringer is substantially flush with the flange portion 406 of the adjacent molded stringer 400 (eg, within 0.010 inch). A joint surface 408 defined by a flange portion 406 and a frame filler portion 340 of 400 is illustrated.

With reference to FIGS. 37 and 38, an example of a composite structure 450 configured as a fuselage barrel portion 452 with a plurality of preformed stringers 400 generally oriented longitudinally is shown. Further, the fuselage barrel portion 452 includes a plurality of axially spaced outer frame 420s, as well as a preformed stringer 400 and an outer skin panel 456 extending 360 degrees around the outer frame. At least a portion of the frame may have a generally circular (eg, elliptical) cross-sectional shape. The outer frame 420 may be connected to the joint surface 408 defined by the flange portion 406 and the frame filler portion 340 of the molded stringer 400. Similar to the above arrangement shown in FIGS. 34 to 36, the outer frame 420 of the fuselage barrel portion 452 can be mechanically fixed to the outer panel 466, the flange portion 406 of the molded stringer 400 and the frame filler portion 340.

Referring to FIGS. 39-41, FIG. 39 shows an exploded perspective view of an embodiment of a stringer laminate 300 having a frame filler outer ply 362 included with one of the frame filler portions 340. As shown in FIG. 40, a frame filler outer ply 362 is added to the frame filler upper ply 348, the frame filler inner ply 355, and the frame filler bottom ply 350 of the stringer laminated plate 300. In order to manufacture the stringer laminate 300 of FIGS. 39-41, the manufacturing system 100 at one or more of the frame filler positions 342 before laying up the frame filler bottom ply 350 at each frame filler position 342. It may include a frame filler external ply laminate head (not shown) configured to lay up one or more frame filler external plies 362 (eg, ply patches) onto the laminate surface 120. After laying up the stringer laminate 300, the stringer laminate 300 has a frame filler outer ply 362 located above the frame filler protrusion 352 and extends over the flange portion 406 of the molded stringer 400, as shown in FIG. It may be formed to be present. To accommodate the larger thickness of the flange portion 406 of the adjacent molded stringer 400 of the composite structure 450, the stringer laminate 300 is one of the frame filler outer plies 362 at one or more frame filler positions 342. Or it can be laid up to include more than one.

FIG. 42 is a top view of an embodiment of the stringer laminated plate 300 having frame filler portions 340 protruding from each of the stringer main body side edges 324 on both sides of the stringer main body portion 320. FIG. 43 is a cross-sectional view of the stringer laminated plate 300 cut out at one of the frame filler positions 342, in which the corresponding frame filler inner plies 355 on both sides of the stringer body portion 320 and the stringer body plies 325 arranged side by side are arranged side by side. Shown. The frame filler inner ply 355 and the stringer body ply 325 may be laid up with a width that defines the slope corners 380 on both sides of the stringer body portion 320. In order to manufacture such a stringer laminated plate 300, in the stringer main body ply laminated heads 210, 212, 214 (FIGS. 15, 17, 19), the frame filler bottom ply 350 is the stringer main body portion 320 at each frame filler position 342. The stringer body ply 325 may be configured to lay up so as to extend from each of the stringer body side edges 324 on both sides. The manufacturing system 100 may include additional frame filler inner ply stacking heads (not shown) for laying up the frame filler inner ply 355 on both sides of the stringer body portion 320.

In one embodiment, the manufacturing system 100 is of at least one dual spindle type, as described below, to simultaneously lay up the frame filler inner ply 355 on each side of the frame filler bottom ply 350 at each frame filler position 342. It may include a stacking head 216 (eg, FIG. 46). Further, in the frame filler outer ply laminated head 202 (FIG. 46), the frame filler upper ply 348 protrudes from the stringer body side edges 324 on both sides of the stringer body portion 320, respectively, and the frame filler bottom ply 350 at each frame filler position 342 The frame filler upper ply 348 (FIG. 43) may be configured to lay up at each frame filler position 342 so as to have side protrusions 352 that complement the protrusions 352. In this way, the frame filler inner plies 355 on both sides of the stringer body portion 320 are captured between the frame filler bottom ply 350 and the frame filler top ply 348 at each frame filler position 342.

With reference to FIGS. 44 and 45, in FIG. 44, one embodiment of the molded stringer 400 obtained as a result of molding the stringer laminate 300 having the frame filler portions 340 protruding from each of the side edges 324 of the stringer body on both sides. An example is shown. FIG. 45 shows an embodiment of a panel assembly 454 having a plurality of preformed stringers 400 connected to an outer panel 456. Two of the molded stringers 400 are manufactured without the frame filler portion 340. The remaining molded stringer 400 has a frame filler portion 340 protruding from each of the side edges 324 of the stringer body on both sides. The frame filler portion 340 is dimensioned and configured to extend to the stringer body side edge 324 of the adjacent molded stringer 400 and has another component (eg, the frame flange 422 of the frame 420) (from FIG. 34). FIG. 36) is provided with a joint surface 408 on the same surface for receiving.

With reference to FIGS. 46 and 47, FIG. 46 shows an embodiment of a manufacturing system 100 having a dual spindle laminate head 216. At least one of the above-mentioned frame filler inner ply laminated heads 204, 206, 208 (FIGS. 9, 11, and 13) may be configured as the dual spindle type laminated head 216. As described above, the dual spindle type laminated head 216 can simultaneously laminate a pair of separated frame filler inner plies 355 at each frame filler position 342, as shown in FIG. 47. Alternatively or additionally, at least one of the stringer body ply laminate heads 210, 212, 214 (FIGS. 15, 17, 19) described above may be configured as a dual spindle laminate head 216. This makes it possible to stack two parallel stringer body plies 325 side by side with respect to each other. Each dual spindle type laminate head 216 may include a dual material roll 234. The dual material roll 234 may supply two streams of layup material 236 to the dual cutter assembly 246, respectively. In an embodiment comprising a material 240 lined with a material roll 234, the dual spindle laminate head 216 may include a dual backing layer separator 248 and a dual backing layer recovery drum 252.

Referring to FIGS. 48 to 50, FIG. 48 shows a top view of an embodiment of the manufacturing system 100 in which the laminated surface 120 is a continuous loop laminated belt 126. The laminated surface 120 includes an outer surface of the laminated belt 126 that can move along a direction generally parallel to the distribution direction 254 (FIG. 6) of the laminated head 200. FIG. 49 is a side view of the manufacturing system 100 showing the stringer laminate 300 supported on the laminate belt 126 that is movable below the laminate head 200. FIG. 50 shows an embodiment of a laminated head 200 shown to be supported above the continuous loop laminated belt 126. As described above, the stacking head 200 is configured as a dual spindle type stacking head 216. However, the manufacturing system 100 of FIGS. 48 to 50 may include one or more single spindle configurations of the laminated head 200, as described above. The stacking head 200 is stationary and can be supported by the beam support 112. For example, the support structure for one or more stacked heads 200 may include one or more crossbeams 108 supported by one or more posts 106.

The laminated belt 126 of FIGS. 48 to 50 is applicable to any of the manufacturing systems 100 described above. For example, the stacking heads 200 of FIGS. 48 to 50 may be configured and operated in a manner similar to any of the above embodiments, such as the configurations shown in FIGS. 9 to 22. The laminated belt 126 may be made of an elastically flexible material (eg, rubber, plastic, or other flexible material). Instead of the flexible material, the laminated belt 126 may be made from a series of hinged metal meshes or relatively short rigid plates connected end to end. The laminated belt 126 may be supported by a plurality of rollers 128, at least one of which may be driven by a drive motor (not shown). In addition, the rollers 128 provide rigidity to prevent distortion of the laminated top surface to which the layup material 236 is applied.

Referring to FIGS. 51 to 53, FIG. 51 has a stationary laminated surface 120 and a plurality of laminated heads 200 configured to move on the laminated surface 120 during manufacturing of the stringer laminated plate 300. A top view of an embodiment of the manufacturing system 100 is shown. The stacking heads 200 of FIGS. 51 to 53 may be configured and operated in a manner similar to any of the above arrangements. For example, the laminated head 200 of FIGS. 51 to 53 may be configured in the same manner as the above-described configuration shown in FIGS. 9 to 22. 52 is a side view of the manufacturing system 100 of FIG. 51, and FIG. 53 is a cross-sectional view of the manufacturing system 100. As mentioned above, the laminate surface 120 is stationary and the laminate head 200 is above the laminate surface 120 along a direction generally aligned with the distribution direction 254 (FIG. 6) during the layup of the stringer laminate 300. Is configured to move. In the illustrated embodiment, the stacking head 200 may be supported by a gantry 110 that is movable along the base member 102. For example, the gantry 110 may include a cross beam 108 with both sides connected to a pair of beam supports 112, respectively. The cross beam 108 may be movable perpendicular to the beam support 112. Each beam support 112 may be movable horizontally along a gantry track 114 that may be incorporated into the base member 102. Although shown to be supported by the gantry 110, the laminated head 200 may be any of a variety of configurations including, but not limited to, one or more robotic devices, cantilevered support systems, or other configurations. May be supported by the robot.

With reference to FIG. 54, a flow chart including the steps of method 500 for laying up the stringer laminate 300 is shown. Prior to laying up the stringer laminate 300, the method may include applying a treatment layer 304 to at least one of the laminate surface 120 and the stringer laminate 300. As described above, the manufacturing system 100 optionally stacks one or more treatment materials for applying any of the various treatment materials before, during, or after laying up the stringer laminate 300. It may include a head (not shown). Such treated materials may include adhesive materials, protective materials, or stripping materials. Some treatment materials can aid in the treatment of the stringer laminate 300 after layup. For example, FIGS. 7 to 22 show a protective layer 306 provided to prevent contamination of the outer surface of the stringer laminate 300.

Referring to FIGS. 7 and 8, step 502 of method 500 uses at least one frame filler outer ply stacking head 202 to laminate a plurality of frame filler bottom plies 350 at intervals along the stacking surface 120. However, it includes defining a plurality of frame filler positions 342. In the illustrated embodiment, as shown in FIG. 7, the frame filler outer ply laminating head 202 distributes the composite material 238 having a constant width and moves the plurality of frame filler bottom plies 350 to the laminating table 122 or It is laminated on the treatment layer 304 (for example, the protective layer 306) previously added to the lamination table 122.

Referring to FIGS. 9-14, step 504 of method 500 uses at least one frame filler inner ply stacking head 204 so that the overlapping portion 354 of each frame filler bottom ply 350 frame at each frame filler position 342. It comprises stacking one or more frame filler inner plies 355 on the protrusions 352 of each frame filler bottom ply 350 so as not to be covered by the filler inner plies 355. For example, the first, second, and third frame filler inner ply laminated heads 204, 206, and 208 are first stacked on the protrusion 352 of the frame filler bottom ply 350 at each frame filler position 342. , 2nd and 3rd frame filler inner plies 356, 358, 360 can be continuously laid up.
In a series of laminated heads (eg, FIGS. 7 to 21), the first, second, and third frame filler inner ply laminated heads 204, 206, 208 are generally aligned with each other and one or more. Can be offset laterally with respect to multiple frame filler outer ply laminated heads. Further, at each frame filler position 342, the width of the frame filler inner ply 355 is smaller than the width of the frame filler bottom ply 350, and as a result, the frame filler inner ply 355 covers only the protrusion 352 of the frame filler bottom ply 350. , The overlapping portion 354 of the frame filler bottom ply 350 is temporarily exposed. In some embodiments, step 504 for laminating the frame filler inner ply 355 can be performed using dual spindle laminating heads 216 (FIGS. 46 and 47) and at each frame filler position 342 the frame filler. A pair of inner plies 355 are laid up at the same time in parallel with each other.

With reference to FIGS. 15-20, step 506 of method 500 extends along the laminate surface 120 and overlaps at each frame filler position 342 using at least one stringer body stack head 210, 212, 214. One or more stringer body plies 325 are laminated so as to define a stringer body portion 320 that overlaps the portion 354, and each stringer body ply 325 is arranged side by side with the frame filler inner ply 355. For example, the first, second, and third stringer body ply laminated heads 210, 212, and 214 are stacked on the overlapping portion 354 of the frame filler bottom ply 350 at each frame filler position 342. The second and third stringer body plies 326, 328, 330 can be laid up continuously. The first, second, and third stringer body ply laminated heads 210, 212, 214 are generally aligned with each other, and the first, second, and third frame filler inner ply laminated heads 204, 206, 208. Can be offset laterally with respect to. The composite material 238 distributed by the stringer body ply laminated heads 210, 212, 214 may have a width approximately equal to the difference in width between the frame filler bottom ply 350 and the frame filler inner ply 355. As described above and shown in FIG. 20, each stringer body ply 325 may be arranged side by side with the frame filler inner ply 355. In an embodiment in which the stringer body portion 320 has a relatively large width, step 506 for stacking the stringer body ply 325 may be performed using the dual spindle type stacking head 216 (FIG. 50), whereby the stringer body portion 320 may be executed. Pairs of plies 325 are stacked in parallel with respect to each other.

Referring to FIGS. 7 to 22, in step 506 for laminating the stringer body ply 325, the stringer body portion 320 overlaps with the frame filler bottom ply 350 at each frame filler position 342, resulting in each frame filler bottom ply 350. The stringer body ply laminated heads 210, 212, and 214 are positioned laterally with respect to the frame filler bottom ply 350 so that the projecting portion 352 protrudes from only one of the stringer body side edges 324 of the stringer body portion 320. May include. For example, the above-mentioned stringer laminated board 300 of FIGS. 23 to 25 has a frame filler portion 340 at each frame filler position 342 that protrudes from only one of the stringer main body side edges 324 of the stringer main body portion 320. As shown in FIG. 32, in each molded stringer 400, the frame filler portion 304 (protruding from the stringer body side edge 324) extends to the flange portion 406 of the adjacent molded stringer 400, thereby the other. A joint surface 408 is provided to which the components (eg, the frame of the panel assembly 454 of FIG. 33) can be attached.

In the alternative embodiment shown in FIGS. 42 to 45, in step 506 of laminating the stringer body ply 325, the stringer body portion 320 overlaps with the frame filler bottom ply 350 at each frame filler position 342, resulting in each. The stringer body ply laminated heads 210, 212, and 214 are placed on the frame filler bottom ply 350 so that the protrusions 352 of the frame filler bottom ply 350 project from each of the stringer body side edges 324 on both sides of the stringer body portion 320. It may include positioning on the side. For example, the stringer laminate 300 of FIGS. 42-45 has a frame filler portion 340 at each frame filler position 342 that projects from both stringer body side edges 324 of the stringer body portion 320. As shown in FIG. 45, the frame filler portion 340 protruding from both stringer body side edges 324 of one of the molded stringers 400 extends to the flange portions 406 of the adjacent stringers on both sides of the molded stringer 400. ..

Referring to FIG. 27, in step 506 for laminating the stringer body ply 325, the stringer body ply 325 is laminated so that at least one of the stringer body side edges 324 on both sides is formed as an oblique edge 382. May include. In such a scenario, step 504 for laminating the frame filler inner ply 355 stacks the frame filler inner ply 355 at each frame filler position 342 to complement the beveled edge 382 of the stringer body portion 320. May include defining. In FIG. 27, both stringer body side edges 324 are shown to have oblique edges 382. Referring to FIG. 28, step 504 for laminating the frame filler inner ply 355 stacks the frame filler inner ply 355 so that at least one of the frame filler side edges 344 on both sides is formed as an oblique edge 382. Can include that. In FIG. 28, both frame filler edge edges 344 are formed at non-vertical slope corner angles 380.

With reference to FIGS. 21 and 22, step 508 of method 500 uses the frame filler outer ply stacking head 202 to allow the frame filler inner ply 355 at each frame filler position 342 to be a frame filler bottom ply 350 and a frame filler top. A frame that is captured between the ply 348 and, as a result, the uncured stringer laminate 300 projects laterally from at least one of the stringer body side edges 324 of the stringer body portion 320 at each frame filler position 342. It comprises stacking the frame filler upper ply 348 on the frame filler inner ply 355 at each frame filler position 342 so as to have the filler portion 340. As described above, each frame filler upper ply 348 extends over the width of the stringer body ply 325 and the frame filler inner ply 355 at each frame filler position 342.

In the method 500 of the present disclosure, steps 502, 504, 506, and 508 for laminating the frame filler bottom ply 350, the frame filler inner ply 355, the stringer body ply 325, and the frame filler top ply 348 are end-to-end relationships with each other. A stringer laminate 300 having a desired ply stacking sequence can be produced in the stringer body portion 320 and the frame filler portion 340, which are sequentially carried out by a plurality of arranged stacking heads 200. The ply stacking sequence can be defined by the relative positions of the stacking heads 200 in a series of stacking heads 200.

With reference to FIGS. 39 and 40, method 500 optionally uses a frame filler external ply stacking head 200 (not shown) to position each frame filler before laminating the frame filler bottom ply 350. At 342, at least one frame filler outer ply 362 may be laminated on the laminated surface 120. As shown in FIG. 41 and described above, in the molded stringer 400, the frame filler outer ply 362 is located inside the frame filler so that the frame filler outer ply 362 overlaps the flange portion 406 of the molded stringer 400. It may have at least the same width as the ply 355 and preferably have a width extending into the stringer body portion 320.

Method 500 may include moving either the stacking head 200 or the stacking surface 120 along a direction generally aligned with the distribution direction 254 (FIG. 6) of the stacking head 200 when stacking the plies. Referring to an embodiment of the manufacturing system 100 shown in FIGS. 1 to 4, the method comprises moving the stacking surface 120 below the stacking head 200 along a direction generally aligned with the distribution direction 254. .. In the embodiment of FIGS. 1 to 4, the laminate head 200 may be stationary at least along the distribution direction 254 during the layup of the stringer laminate 300. In the embodiments of FIGS. 1 to 4 and 7 to 21, the method lays up a ply on the outer surface of the stacking table 122 and / or on a ply previously laid up by the stacking head 200. In the meantime, it involves moving the rigid stacking table 122 to the stacking station 198 along at least one direction. In such a configuration, the method may include laying up the stringer laminate 300 while the laminate table 122 passes through the laminate station 198 one or more times. In the embodiment of the manufacturing system 100 shown in FIGS. 48 to 50, moving the stacking surface 120 below the stacking head 200 was previously formed on and / or by the stacking head 200 on the outer surface of the stacking belt 126. It may include moving at least one continuous loop laminating belt 126 below the laminating head 200 while laminating the composite ply 302 on top of the composite ply 302.

In yet another embodiment shown in FIGS. 51-53, the method is oriented in a direction that is generally aligned with the distribution direction 254 (FIG. 6) while the laminate surface 120 is stationary during the layup of the stringer laminate 300. Along, moving the stacking head 200 above the stacking surface 120 may be included. In such an embodiment, the stacking head 200 may be movable on the stacking surface 120 via the gantry 110, which is movable along the gantry track 114, as described above.

In addition, the disclosure includes examples described in the provisions listed below.

Clause A1
A manufacturing system (100) for laying up a stringer laminated board (300), in which a composite material (240) is distributed along a laminated surface (120) and a distribution direction (254), and the composite material (240) is distributed in the distribution direction (120). Ply is laminated on the laminated surface (120) and the previously formed ply during the relative movement between the laminated surface (120) and the laminated head (200) along a direction generally aligned with 254). A plurality of laminated heads (200) configured as described above, a plurality of frame filler bottom plies (350) are laminated at intervals along the laminated surface (120), and a plurality of frame filler positions (342) are laminated. The overlapping portion (354) of at least one frame filler outer ply laminated head (202) and each frame filler bottom ply (350) configured to define the frame filler inner ply at each frame filler position (342). One or more of the frame filler inner plies (355) are laminated on the protrusions (352) of the frame filler bottom ply (350) at each frame filler position (342) so as not to be covered by (355). A stringer extending along the laminated surface (120) and overlapping the overlapping portion (354) at each frame filler position (342) with at least one frame filler inner ply laminated head (206) configured to do so. At least one configured to stack one or more stringer body plies (325) defining the body portion (320) and arranging each stringer body ply (325) side by side with the frame filler inner ply (355). One stringer body laminated head (210, 212, 214) and the one or more frame filler inner plies (355) at each frame filler position (342) are frame filler bottom ply (350) and frame filler top ply (35). Each so that the uncured stringer laminate (300) has a plurality of frame filler portions (340) projecting laterally from the stringer body portion (320) as a result of being captured with and from the stringer body portion (320). With the frame filler outer ply lamination head (202) configured to laminate the frame filler upper ply (348) on the one or more frame filler inner plies (355) at the frame filler position (342). Multiple laminated heads (200) including The manufacturing system (100) provided.

Clause A2
The plurality of laminated heads (200) are positioned end-to-end with each other, and the frame filler bottom ply (350), the frame filler inner ply (355), the stringer body ply (325), and the frame filler upper portion. Clause A1, wherein the plies (348) are laminated to produce the stringer laminate (300) in a desired ply stacking sequence defined by the position of the plurality of laminate heads (200) relative to each other. The manufacturing system (100) described.

Clause A3
The plurality of laminated heads (200) are stationary, and the laminated surface (120) is oriented along a direction generally aligned with the distribution direction (254) during the lamination of the stringer laminated board (300). The manufacturing system (100) according to clause 1 or 2, which is configured to move below the stacking head (200).

Clause A4
The laminated surface (120) is the outer surface of at least one rigid laminated table (122) movable below the laminated head (200), and the continuous loop laminated belt (200) movable below the laminated head (200). 126) The manufacturing system (100) according to clause A3, which comprises one of the outer surfaces.

Clause A5
The stacking surface (120) is stationary, and the plurality of stacking heads (200) are oriented along a direction generally aligned with the distribution direction (254) during the stacking of the stringer laminates (300). The manufacturing system (100) according to any one of clauses A1 to A4, which is configured to move above the laminated surface (120).

Clause A6
In the at least one stringer body laminated head (210, 212, 214), the protrusion (352) of each frame filler bottom ply (350) has the stringer body side edges (324) on both sides of the stringer body portion (320). ), The manufacturing system (100) according to any one of clauses A1 to A5, which is configured to stack the stringer body portions (320) so as to project from a single side edge.

Clause A7
In the at least one stringer main body laminated head (210, 212, 214), the protruding portion (352) of each frame filler bottom ply (350) has a stringer main body side edge (324) on both sides of the stringer main body portion (320). ), The manufacturing system (100) according to any one of Articles A1 to A6, which is configured to stack the stringer main body portions (320) so as to protrude from each of the above.

Clause A8
At least one stringer body laminate head (210, 212, 214) and / or at least one frame filler inner ply laminate head (206) is a pair of separated and parallel stringer body plies (325) and a separated and parallel frame. The manufacturing system (100) according to Clause A7, which is configured as a dual-spindle laminate head (200) configured to laminate a pair of filler inner plies (355) at the same time.

Clause A9
The stringer body ply (210, 212, 214) is such that at least one of the side edges (324) of the stringer body on both sides is formed as an oblique edge (382). The frame filler inner ply stacking head (206) is configured to stack 325) so as to define a slope corner (380) that complements the angled edge (382) of the stringer body portion (320). The manufacturing system (100) according to any one of Articles A1 to A8, wherein the frame filler inner ply (355) is laminated at each frame filler position (342).

Clause A10
The laminated surface (120) at one or more of the frame filler positions (342) before the plurality of laminated heads (200) laminate the frame filler bottom ply (350) at each frame filler position (342). ), The manufacturing system (100) according to any one of clauses A1 to A9, comprising a frame filler external ply stacking head (200) configured to laminate at least one frame filler external ply (362). ).

Clause B1
A method of laying up a stringer laminate (300) using at least one frame filler outer ply laminate head (202) and a plurality of frame filler bottom plies spaced along the laminate surface (120). Stacking (350) to define multiple frame filler positions (342) and using at least one frame filler inner ply stacking head (206) to overlap each frame filler bottom ply (350) One or more of the frames above the protrusions (352) of each frame filler bottom ply (350) so that the 354) is not covered by the frame filler inner ply (355) at each frame filler position (342). Stacking the filler inner plies (355) and using at least one stringer body stacking head (210, 212, 214) extend along the stacking surface (120) and at each frame filler position (342). ), One or more stringer body plies (325) are laminated so as to define the stringer body portion (320) that overlaps with the overlapping portion (354), and each stringer body ply (325) is used as a frame filler inner ply. By arranging side by side with (355) and using the frame filler outer ply laminated head (202), the one or more frame filler inner plies (355) at each frame filler position (342) are framed. A plurality of uncured stringer laminates (300) are trapped between the filler bottom ply (350) and the frame filler top ply (348) so that the uncured stringer laminate (300) projects laterally from the stringer body portion (320). Laminating the frame filler upper ply (348) on the one or more frame filler inner plies (355) at each frame filler position (342) so as to have the frame filler portion (340). To move either the stacking head (200) or the stacking surface (120) along a direction generally aligned with the distribution direction (254) of the stacking head (200) while stacking the plurality of plies. How to include.

Clause B2
The step of stacking the plurality of plies is sequentially performed by the plurality of stacking heads (200) arranged in an end-to-end relationship with each other, and the desired position defined by the positions of the plurality of stacking heads (200) with respect to each other. The method of clause B1, wherein stringer laminates (300) having a ply stacking sequence are laminated.

Clause B3
Moving either the stacking head (200) or the stacking surface (120) is along a direction generally aligned with the distribution direction (254) while the plurality of stacking heads (200) are stationary. The method according to clause B1 or B2, which comprises moving the laminated surface (120) below the laminated head (200).

Clause B4
Moving the laminated surface (120) below the laminated head (200) allows the ply to be moved to the outer surface of the ply laminated table (122) and to the ply previously formed by the laminated head (200). The rigid laminating table (122) is moved below the laminating head (200) while laminating on top, and the plies are preliminarily driven by the outer surface of the laminating belt (126) and the laminating head (200). The method of clause B3, comprising one of moving at least one continuous loop laminated belt (126) below the laminated head (200) while laminating on the ply formed in. ..

Clause B5
Moving either the stacking head (200) or the stacking surface (120) is along a direction generally aligned with the distribution direction (254) while the stacking surface (120) is stationary. The method according to any one of clauses B1 to B4, comprising moving the laminated head (200) above the laminated surface (120).

Clause B6
Laminating the one or more stringer body plies (325) so as to define the stringer body portion (320) can cause the at least one stringer body stacking head (210, 212, 214) to be laminated to the frame filler. Positioned laterally to the bottom ply (350) so that the stringer body portion (320) overlaps the frame filler bottom ply (350) at each frame filler position (342), resulting in each frame filler. Any of claims B1 to B5, comprising projecting the protrusion (352) of the bottom ply (350) from a single side edge of the stringer body side edges (324) on either side of the stringer body. The method described in paragraph 1.

Clause B7
Laminating the one or more stringer body plies (325) so as to define the stringer body portion (320) can cause the at least one stringer body stacking head (210, 212, 214) to be laminated to the frame filler. Positioned laterally to the bottom ply (350) so that the stringer body portion (320) overlaps the frame filler bottom ply (350) at each frame filler position (342), resulting in each frame filler. The method according to any one of claims B1 to B6, wherein the protruding portion (352) of the bottom ply (350) protrudes from each of the side edges (324) of the stringer body on both sides of the stringer body. ..

Clause B8
Laminating the one or more stringer body plies (325) and laminating the one or more frame filler inner plies (355) are each of the at least one stringer body laminating head (210). , 212, 214) to stack the stringer body plies (325) so that at least one of the stringer body side edges (324) on both sides is formed as an angled edge (382). Each frame filler position (342) uses the frame filler inner ply laminate head (206) to define a slope corner (380) that complements the angled edge (382) of the stringer body portion. The method according to any one of Articles B1 to B7, comprising laminating the frame filler inner ply (355) in the above.

Clause B9
Further comprising applying the treated material (240) to at least one of the laminated surface (120) and the stringer laminate (300) using at least one treated material (240) laminate head (200). The method according to any one of Articles B1 to B8, wherein the treatment material (240) comprises at least one of an adhesive material (240), a protective material (240), and a release material (240).

Clause C1
A method of laying up a stringer laminate (300), in which a plurality of frame filler bottom plies (350) are laminated at intervals along a laminate surface (120) to define a plurality of frame filler positions (342). And one of the frame filler bottom plies (350) so that at least one overlapping portion (354) of the frame filler bottom ply (350) is not covered by the frame filler inner ply (355). Alternatively, at least one frame filler inner ply (355) is laminated on the plurality of protrusions (352), and one of the frame filler positions (342) extending along the laminated surface (120). Alternatively, at least one stringer body ply (325) is laminated and at least one of the frame filler positions (342) so as to define a stringer body portion (320) that overlaps the overlapping portion (354) in a plurality of pieces. One or one of the frame filler positions (342) so that the at least one frame filler inner ply (355) is captured between the frame filler bottom ply (350) and the frame filler top ply (348). A method comprising laminating the frame filler upper ply (348) on the at least one frame filler inner ply (355) in a plurality.

Additional amendments and improvements to this disclosure may be apparent to those skilled in the art. Accordingly, a particular combination of parts described and shown herein is intended only to represent a particular embodiment of the present disclosure and is an alternative embodiment within the spirit and scope of the present disclosure. Or, the device is not limited.

Claims (15)

A manufacturing system (100) for laying up a stringer laminated board (300).
The composite surface (120) and the stack head (200) are distributed along the stacking surface (120) and the distribution direction (254) and along a direction generally aligned with the distribution direction (254). A plurality of laminated heads (200) configured to laminate the ply on the laminated surface (120) and the previously formed ply during the relative movement with the (200).
A plurality of frame filler bottom plies (350) are laminated at intervals along the laminated surface (120), and at least one frame filler outer ply laminate configured to define a plurality of frame filler positions (342). With the head (202),
The frame filler bottom at each frame filler position (342) so that the overlapping portion (354) of each frame filler bottom ply (350) is not covered by the frame filler inner ply (355) at each frame filler position (342). At least one frame filler inner ply lamination head (206) configured to laminate one or more of the frame filler inner plies (355) onto the protrusions (352) of the ply (350).
One or more stringer body plies (325) extending along the laminated surface (120) and defining a stringer body portion (320) that extends along the laminated surface (120) and overlaps the overlapping portion (354) at each frame filler position (342). At least one stringer body laminated head (210, 212, 214) configured to be laminated so that each stringer body ply (325) is arranged side by side with the frame filler inner ply (355).
The one or more frame filler inner plies (355) at each frame filler position (342) are captured between the frame filler bottom ply (350) and the frame filler top ply (348), resulting in uncured. One or more frames at each frame filler position (342) such that the stringer laminate (300) has a plurality of frame filler portions (340) protruding laterally from the stringer body portion (320). A plurality of laminated heads (200) including the frame filler outer ply laminated head (202) configured to laminate the frame filler upper ply (348) on the filler inner ply (355).
Manufacturing system (100). The plurality of laminated heads (200) are positioned end-to-end with each other, and the frame filler bottom ply (350), the frame filler inner ply (355), the stringer body ply (325), and the frame filler upper portion. 1. The stringer laminate (300) is configured to laminate the plies (348) and generate the stringer laminate (300) in a desired ply laminate sequence defined by the position of the plurality of laminate heads (200) with respect to each other. The manufacturing system (100) according to. The plurality of laminated heads (200) are stationary, and the laminated surface (120) is oriented along a direction generally aligned with the distribution direction (254) during the lamination of the stringer laminated board (300). The manufacturing system (100) according to claim 1 or 2, which is configured to move below the stacking head (200). The laminated surface (120) is stationary, and the plurality of laminated heads (200) are aligned with the distribution direction (254) during the lamination of the stringer laminated plate (300). The manufacturing system (100) according to any one of claims 1 to 3, which is configured to move above the laminated surface (120). In the at least one stringer main body laminated head (210, 212, 214), the protruding portion (352) of each frame filler bottom ply (350) has a stringer main body side edge (324) on both sides of the stringer main body portion (320). The manufacturing system (100) according to any one of claims 1 to 4, wherein the stringer main body portion (320) is laminated so as to protrude from a single side edge of the above. .. In the at least one stringer main body laminated head (210, 212, 214), the protruding portion (352) of each frame filler bottom ply (350) has a stringer main body side edge (324) on both sides of the stringer main body portion (320). The manufacturing system (100) according to any one of claims 1 to 5, wherein the stringer main body portion (320) is laminated so as to protrude from each of the above. The stringer body ply (210, 212, 214) is such that at least one of the stringer body side edges (324) on both sides is formed as an oblique edge (382). 325) is configured to be laminated
At each frame filler position (342), the frame filler inner ply laminated head (206) defines a slope corner (380) that complements the angled edge (382) of the stringer body portion (320). The manufacturing system (100) according to any one of claims 1 to 6, wherein the frame filler inner ply (355) is configured to be laminated. The laminated surface (120) at one or more of the frame filler positions (342) before the plurality of laminated heads (200) laminate the frame filler bottom ply (350) at each frame filler position (342). The manufacturing system according to any one of claims 1 to 7, further comprising a frame filler external ply lamination head (200) configured to laminate at least one frame filler external ply (362) on the frame filler external ply (362). 100). A method of laying up a stringer laminated board (300).
Using at least one frame filler outer ply laminating head (202), a plurality of frame filler bottom plies (350) are laminated at intervals along the laminating surface (120) to multiple frame filler positions (342). To define and
Using at least one frame filler inner ply laminate head (206), the overlap (354) of each frame filler bottom ply (350) is covered by the frame filler inner ply (355) at each frame filler position (342). One or more of the frame filler inner plies (355) are laminated on the protrusions (352) of each frame filler bottom ply (350) so as not to be damaged.
Using at least one stringer body stacking head (210, 212, 214), the stringer body extends along the stacking surface (120) and overlaps the overlapping portion (354) at each frame filler position (342). One or more stringer body plies (325) are laminated so as to define the portion (320), and each stringer body ply (325) is arranged side by side with the frame filler inner ply (355).
Using the frame filler outer ply laminated head (202), the one or more frame filler inner plies (355) at each frame filler position (342) are frame filler bottom ply (350) and frame filler top ply. Captured between (348) and, as a result, the uncured stringer laminate (300) has a plurality of frame filler portions (340) that project laterally from the stringer body portion (320). Laminating the frame filler upper ply (348) on the one or more frame filler inner plies (355) at each frame filler position (342).
While stacking the plurality of plies, moving either the stacking head (200) or the stacking surface (120) along a direction generally aligned with the distribution direction (254) of the stacking head (200). And how to include. The step of stacking the plurality of plies is sequentially performed by the plurality of stacking heads (200) arranged in an end-to-end relationship with each other, and is defined by the positions of the plurality of stacking heads (200) with respect to each other. 9. The method of claim 9, wherein stringer laminates (300) having a ply stacking sequence are laminated. Moving either the laminated head (200) or the laminated surface (120)
While the plurality of laminated heads (200) are stationary, moving the laminated surface (120) below the laminated head (200) along a direction generally aligned with the distribution direction (254). The method according to claim 9 or 10, which includes. Moving either the laminated head (200) or the laminated surface (120)
This includes moving the stacking head (200) above the stacking surface (120) along a direction generally aligned with the distribution direction (254) while the stacking surface (120) is stationary. The method according to any one of claims 9 to 11. Stacking the one or more stringer body plies (325) so as to define the stringer body portion (320) can be done.
The at least one stringer body laminated head (210, 212, 214) is positioned laterally with respect to the frame filler bottom ply (350), and at each frame filler position (342), the stringer body portion (320) is The frame filler bottom ply (350) is overlapped so that the protrusion (352) of each frame filler bottom ply (350) is a single of the stringer body side edges (324) on both sides of the stringer body. The method of any one of claims 9-12, comprising projecting from one side edge. Stacking the one or more stringer body plies (325) so as to define the stringer body portion (320) can be done.
The at least one stringer body laminated head (210, 212, 214) is positioned laterally with respect to the frame filler bottom ply (350), and at each frame filler position (342), the stringer body portion (320) is The frame filler bottom ply (350) is overlapped so that the protrusions (352) of each frame filler bottom ply (350) protrude from each of the stringer body side edges (324) on both sides of the stringer body. The method according to any one of claims 9 to 13, wherein the method comprises the above. Further comprising applying the treated material (240) to at least one of the laminated surface (120) and the stringer laminate (300) using at least one treated material (240) laminate head (200). ,
The method according to any one of claims 9 to 14, wherein the treatment material (240) comprises at least one of an adhesive material (240), a protective material (240), and a release material (240).

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